Method for processing grain and legume fully-cooked powders and snacks

Abstract

Grain or legume material is precooked by a low moisture process and preconditioned by hydrating to a total moisture content of from about 10% to about 40% by weight, passed through a cooking extruder and, during such passage, hydrated to a total moisture content of from about 10% to about 40% by weight, extruded and dried. The products of the invention are crisp curls, puffs and chips. The extruded cooked material may also be ground and agglomerated to prepare powders which will not cake or lump.

Having described the preferred embodiments of the present invention, the following is claimed as new and desired to be secured by Letters Patent: 
     
       1. A method for processing a food material into a cooked powder or snack product, comprising the steps of: (a) precooking the material by energizing the food material with energy in an infrared range sufficient to partially cook the material and reduce the total moisture content of the food material to about 5% to about 10%;   (b) preconditioning the material by hydrating the material to a total moisture content of from about 10% to about 40% by weight;   (c) passing the material into and through an extruder, and during such passage cooking the material;   (d) extruding the material to form an expanded cellular extrudate; and   (e) drying said extrudate to a total moisture content of about 5% to about 15% by weight.   
     
     
       2. The method as set forth in claim 1, further including the step of selecting a food material from the group consisting of grains, edible beans, peas, lentils and mixtures thereof. 
     
     
       3. The method as set forth in claim 1, further including the step of adding a supplemental ingredient selected from the group consisting of seasonings, oil and processing aids, mixtures thereof. 
     
     
       4. The method as set forth in claim 1, wherein the precooking of step (a) reduces the total moisture content of the food material to about 5% to about 10%. 
     
     
       5. The method as set forth in claim 1, wherein after step (a) and before step (b) the material is preconditioned by hydrating to a total moisture content of from about 10% to about 40% by weight. 
     
     
       6. The method as set forth in claim 1, wherein step (a) comprises energizing the food material with energy in the infrared range sufficient to partially cook the material. 
     
     
       7. The method as set forth in claim 1, wherein the material is cooked in step (b) until at least about 95% of the starch is gelatinized. 
     
     
       8. The method as set forth in claim 1, further including the steps of: (e) after step (c), flaking said extrudate;   (f) after step (d), cooling said extrudate;   (g) grinding said extrudate to form a powder; and   (h) agglomerating the powder.   
     
     
       9. The method as set forth in claim 1, the powder having a final moisture content of from about 5% to about 15% by weight. 
     
     
       10. A method for processing a a starch-containing food material selected from the group consisting of grains, edible beans, peas, lentils and mixtures thereof into a cooked powder or snack product, comprising the steps of: (a) precooking the material by energizing the food material with energy in an infrared range sufficient to partially cook the material and reduce the total moisture content of the food material to about 5% to about 10%;   (b) preconditioning the material by hydrating the material to a total moisture content of from about 10% to about 40% by weight;   (c) passing the precooked and preconditioned material into and through an extruder and, during such passage, cooking the material;   (d) extruding the material to form an expanded cellular extrudate; and   (e) drying said extrudate to a total moisture content of about 5% to about 15% by weight.   
     
     
       11. The method as set forth in claim 10, further including the step of selecting a food material from the group consisting of grains, edible beans, peas, lentils and mixtures thereof. 
     
     
       12. The method as set forth in claim 10, further including the step of adding a supplemental ingredient selected from the group consisting of seasonings, oil and processing aids, mixtures thereof. 
     
     
       13. The method as set forth in claim 10, wherein precooking in step (a) reduces the total moisture content of the food material to about 5% to about 10%. 
     
     
       14. The method as set forth in claim 10, wherein step (a) comprises energizing the food material with energy in an infrared range sufficient to partially cook the material. 
     
     
       15. The method as set forth in claim 10, wherein the material is cooked in step (c) until at least about 95% of the starch is gelatinized. 
     
     
       16. The method as set forth in claim 10, further including the steps of: (f) after step (d), flaking said extrudate;   (g) after step (e), cooling said extrudate;   (h) grinding said extrudate to form a powder; and   (i) agglomerating the powder.   
     
     
       17. The method as set forth in claim 10, the powder having a final moisture content of from about 5% to about 15% by weight. 
     
     
       18. A method for processing a starch-containing food material selected from the group consisting of grains, edible beans, peas, lentils and mixtures thereof into a cooked powder or snack product, comprising the steps of: (a) precooking by energizing the food material with energy in an infrared range sufficient to partially cook the material and reduce the total moisture content of the food material to about 5% to about 10%;   (b) preconditioning the material by hydrating the material to a total moisture content of from about 10% to about 40% by weight;   (c) passing the material into and through an extruder and, during such passage, subjecting the material to an elevated cooking temperature until at least about 95% of the starch is gelatinized;   (d) extruding the material to form an expanded cellular extrudate;   (e) flaking said extrudate;   (f) drying said extrudate to a total moisture content of about 5% to about 15% by weight;   (g) cooling said extrudate;   (h) grinding said extrudate to form a powder; and   (i) agglomerating the powder.   
     
     
       19. The method as set forth in claim 18, further including the step of adding an ingredient selected from the group consisting of seasonings, oil, processing aids and mixtures thereof.